Rotary envelope making machine having interchangeable sections



$3 & mw a July 1, 1969 E. B. BERKLEY ROTARY ENVELOPE MAKING MACHINEHAVING INTERCHANGEABLE SECTIONS Filed Feb. 23, 1967 INVENTOR.

J Eugene Barf/'0!!! Berk/g y 1969 E. B. B ERKLEY 3,452,652

ROTARY ENVELOPE MAKING MACHINE HAVING INTERCHANGEABLE SECTIONS FiledFeb. 23, 1967 Sheet 3 of 2 United States Patent 3,452,652 ROTARYENVELOPE MAKING MACIHNE HAV- ING INTERCHANGEABLE SECTIONS Eugene BertramBerkley, Shawnee Mission, Kans., as-

signor to Tension Envelope Corporation, Kansas City,

Mo., a corporation of Delaware Filed Feb. 23, 1967, Ser. No. 618,018Int. Cl. B31b 21/26, 21/14, 21/74 US. Cl. 93-62 3 Claims ABSTRACT OF THEDISCLOSURE This invention relates to a rotary envelope making machinehaving interchangeable units in which various operations are performedon envelope blanks, such as feeding, printing, cutting window openings,applying patches, applying adhesive, collating the blanks to applyadhesive to the closure flaps, decollating the blanks, scoring theblanks preparatory to making the folds of the flap portions, folding theside flap portions, applying the side seam adhesive, and folding thebottom and closure flap portions. The mechanisms for accomplishing thesefunctions are all positioned in consecutive order and various componentsmust operate in timed relation with travel of the blanks, in order thatthe operations are performed in proper places on the blanks to makesatisfactory envelopes.

It is obvious that the components of such mechanisms must all beadjusted and retimed when changing over from one size and/ or style ofenvelope to another. These adjustments are complicated and must beextremely accurate. This also requires adjustment and readjustments ofthe components relatively to each other to get them working in propertime. The adjustments and servicing of the units require experttechnicians. In addition, the time required in making the adjustmentsis, for example, from four to sixteen hours, during which time themachine is not producing. Consequently, the cost in investment, laborand loss in operating time makes orders for special sizes and/or stylesof envelopes in quantities of 25,000 to 100,000 impractical.

The principal objects of this invention are: to provide the machine withremovable units or sections, whereby a unit can be easily removed andreplaced by a preadjusted unit when it is necessary to change over fromone size and/or style of envelope to another; to provide suitable workbenches or supports along sides of the envelope making machine that areequipped with means for manually turning the mechanisms when making therequired adjustments; to provide an arrangement of work benches so thatan empty bench is available to receive the unit from the machine toclear the machine for a preadjusted unit which has been adjusted to thesize of the envelope blanks for the next run; and to provide travelingconveyor means for moving the units to and from the work bench means.

In accomplishing these and other objects of the invention as hereinafterdescribed, I have provided improved structure, illustrated in theaccompanying drawings, wherein:

3,452,652 Patented July 1, 1969 FIG. 1 is a longitudinal section showingthe invention with one of the removable sections being moved from themachine to one of the work bench means, and on which the unit is readilyadjusted to produce a different size and/or style of envelope, withoutinterference with operation of the envelope making machine, the sectionbeing taken on the line 11 of FIG. 2.

FIG. 2 is a cross section taken on the line 2-2 of FIG. 1, to show thearrangement of work benches relatively to the envelope making machinewhere a unit that has been adjusted for a new run of envelopes is readyand waiting to be transferred to its place in the envelope makingmachine.

FIG. 3 is a diagrammatic plan view of the envelope making machine,illustrating an arrangement of work benches.

FIG. 4 is a plan view of two different sizes and styles of blanks,superimposed one on the other to better i1lustrate the adjustments thatwill be required.

FIGS. 5 and 6 are plan views of the different operations that areperformed on an envelope blank in making an envelope, all of which areperformed in consecutive order progressive with conveyance of the blankthrough the various mechanisms of the envelope making machine.

FIGS. 7 and 8 are side and face views, respectively, of a portion of thedrive chain for one of the removable units, to illustrate one way ofdisconnecting the drive of the unit from the main drive of the envelopemaking machine.

FIG. 9 is a fragmentary section through one means for anchoring aremovable unit to the frame of the machine and to the work bench means.

Referring more in detail to the drawings:

1 designates an envelope making machine having replaceable sections orunits in accordance with the present invention and designated generallyby the numerals 2, 3 and 4. The sections 2, 3 and 4 contain theoperating mechanisms of the envelope making machine that require thegreatest time in making precision adjustments when changing the machinefrom a run of one size and/or type of envelopes for a run of differentsize and/or type of envelopes, for example, as represented in FIG. 4 bythe blanks 5 and 6.

The machine illustrated has side frames 7 and 8 suitably connected andsupported on a base 9 mounted on a floor 10. The side frames 7 and 8 areprovided with seats 11, 12 and 13 for seating side frames 14 and 15 ofthe respective sections. The sections 2, 3 and 4 are suitably anchoredto the seats of the side frames 7 and 8, for example, by fasteningdevices such as cap screws 16 that extend through ears 17 and threadedinto bosses 18 on the respective side frames 7 and 8, as bestillustrated in FIG. 9.

The section 2 carries a stack support 19 for carrying a stack of blanks,for example, the blanks 5, for making one type and size of envelopes 20(see FIG. 6) The blanks 5 are ordinarily died from paper stock toprovide a front panel portion 21, side flap portions 22. and 23, andbottom and closure flaps 24 and 25 (see FIGS. 5 and 6). If the blanksare to be printed on the exterior or interior sides, the section 2 alsocarries printing mechanisms 26 and 27. If the front panel portions ofthe blanks are to have window openings 28 formed therein, the section 2may carry a Window cutting mechanism 29.

The blanks are withdrawn one at a time from the stack support 19 and fedby a system of rollers into contact with the printing mechanisms 26 and27 and window cutter 29, from which they are advanced to the section 3.

The section 3 carries an adhesive applying mechanism 30 for applyingadhesive 31 around the window opening 28 for attaching a patch 32 (FIG.5) applied by a patch mechanism generally designated 33, also carried byand forming a part of the section 3 (FIG. 1). As in conventional rotarywindow envelope making machines, the blanks are collated to applyadhesive 34 (FIG. 6) to the closure flaps of the blanks by an adhesiveapplicator (FIG. 1). The direction of the blanks is reversed, so thatthe blanks are carried through a drying chamber 36 to the opposite end37 of the machine 1, where the blanks are decollated by a decollatingmechanism 38 and timed for scoring and folding of the flaps intoenvelopes.

The decollating mechanism 38 forms a part of the section 4 in which theblanks are conveyed through a scoring mechanism 39 also carried by thesection 4, for forming longitudinal scores 40 and 41 and transversescores 42 and 43 (FIG. 6) to define the front panel of the envelope andprovide lines of fold for the side, bottom and closure flaps. Thesection 4 also carries a side flap folding mechanism 44 (FIG. 1) whichfolds the side flaps over the inner face of the front panel, as shown inFIG. 6. The section 4 also includes an adhesive applicator 45 forapplying adhesive stripes 46 and 47 to the folded-over side flaps 22 and23, also shown in FIG. 6. The section 4 also includes a bottom flapfolding mechanism 48 to fold the bottom flaps 24 on the transverse score40 in overlying relation with the side flaps and in sealing contact withthe adhesive stripes 46 and 47. After folding over the bottom flaps 24,the blanks are passed to a trap 49, where the direction is reversed tofold over the closure flaps on the transverse lines of score 41 by afolding mechanism 50, also carried by the section 4. The foldedenvelopes are then delivered onto a work table 51, where they areinserted in boxes by the machine operator who stands alongside the worktable portion of the machine.

All of the various mechanisms of the envelope making machine thus fardescribed, including the mechanisms of sections 2, 3 and 4, are drivenby a motor 52 suitably connected with a countershaft 53 by drivingconnections 54. The sections 2 and 3 carry transverse shafts 55 and 56having sprockets 57, 58 indicated by the dotted lines in FIG. 1. Thecountershaft 53 has sprockets 59 and 60 aligning with the sprockets 55and 56. Operating over the sprockets 57 and 59 is a chain 61, and thesprockets 58 and 60 are connected by a similar chain 62. The variousmechanisms on the sections 2 and 3 are driven by driving connectionssuch as gears with the shafts 55 and 56 in suitable manner to operatethe mechanisms in timed relation. A longitudinal shaft 63 has a drivingconnection with the countershaft 53 to drive a countershaft 64 whichcarries a sprocket 65 on the countershaft aligning with a sprocket 66 ona transverse shaft 67 carried by the section 4. Operating over thesprockets 65 and 66 is a chain 68 (FIG. 2). The chains 61,62 and 68 haveremovable links 69, as shown in FIG. 7, whereby the chains may bedisconnected when the sections 2, 3 and 4 are to be removed and replacedby similar sections in accordance with the present invention.

With the exception of the removable sections 2, 3 and 4, all of thestructure thus far described may be a part of any existing rotaryenvelope making machine, and the various drives, of course, vary Withthe particular type of machine to which the present invention isadapted. However, all envelope making machines will have similar drivingmechanisms and the operating mechanisms on the blanks will be of variousconstructions, so that it is to be understood that the invention is notrestricted to the particular structure shown.

As above explained, changing theadjustments of the various mechanisms toset the machine up for a run of a certain size and/ or style of envelopeblank requires from four to sixteen hours, during which time the machineis out of production.

The present invention is to maintain the machine in substantiallycontinuous production by providing similar sections that can be adjustedalongside or near the envelope making machine while the machine is inproduction, and

which are later replaced with the sections in the machine.

To facilitate support of the sections under adjustment for a differentsize and/or style of envelope, for example, an envelope made from theblank 6 of FIG. 4, the invention contemplates a bench means along oneside of the machine, as indicated at 70 and 71, FIG. 3. Similar benchmeans are located at the opposite side of the machine, as indicated at72 and 73, to receive thereon the sections 2, 3 and 4 from the machinewhen the machine is to be cleared for the preadjusted sections on thebench means 70 and 71.

The bench means 70 and 72 are preferably located in spaced registry withthe sections 2 and 3 to support both sections. The bench means 71 and 73are in laterally spaced relation with the section 4. The space 74 alongthe back side of the envelope making machine may be only that requiredto readjust the sections, however, the

- space on the operators side of the machine is wider to provide aservice area 75 for the machine and also permit a mechanic to adjust andservice the sections mounted on the bench means 70 and 71 withoutinterfering with the. machine operators work.

Each bench means has side frames 76 and 77 conforming to the side framesof the envelope making machine, and which are mounted on bases 78 sothat the upper edges 79 of the frames 76 and 77 are at substantially thesame level as the seats 11, 12 and 13 to seat the sides 14 and 15 of thesections thereon. The side frames 76 and 77 also have internallythreaded bosses 80 to receive the fastening devices 16, so that thesections may be anchored on the benches substantially in the same manneras they are anchored on the side frames of the envelope making machine.

The benches also have countershafts 81, similar to the shafts 55, 56 and64 of the envelope making machine. The countershafts -81 carry asprocket 82 that aligns with the sprockets 57, 58 and 65, so that chains83 may be run thereover to connect the countershafts 81 of the bencheswith the drive sprocket of the section mounted thereon, in exactly thesame manner as they are connected in the envelope making machine. Thecountershafts have hand wheels 84 on one outer end thereof for manualrotation of the mechanisms of the sections to facilitate adjustmentthereof and feed of the envelope blanks through the sections.

Transfer of the sections to and from their seats in the envelope makingmachine is effected by conveying means which in the illustrated instanceincludes overhead tracks 85, 86 and 87 located over the respectivesections 2, 3 and 4 and having opposite ends 88 and 89 extending acrossthe bench means, as shown in FIGS. 1 and 2. The tracks have upper andlower flanges 90 and 91 connected by a web 92 to provide ways 93 on therespective sides of the web. Operable in the ways are the wheels 95 oftrolleys 96, 97 and 98. Carried by each trolley is a hoist 99 includinga tackle 100 having a tackle block 101 equipped with a hook 102. Thebook 102 carries a spreader bar 103 having chains 104 adapted to befastened to eyes 105 at the respective corners of the section, wherebythe sections may be fastened to the hoist. The hoists are preferablyactuated by an electric motor 106 under control of a depending switch107.

Assume that the envelope making machine has been operating for makingthe envelopes 20 from the blanks 5, and that the run has been completed.While the machine was in operation, extra sections 2, 3 and 4, which areon the bench means 70 and 71, were adjusted for operation on the nextrun of envelopes, for example, envelopes to be made from the blanks 6.

The sections 2, 3 and 4 are released from the frame of the envelopemaking machine by unscrewing the cap screws 16 and disconnecting thedrive chains 61, 62 and 68 at the removable links 69.

The hoists 99 are then moved on the tracks 85, 86 and 87 to center thespreader bars 103 over the sections 2, 3

and 4 that are to be removed. The hooks in the ends of the chains 104are engaged with the eyes 105 in the frames of the sections, to lift thesections clear of the machine, as shown in FIG. 1. The sections,suspended from the trolleys, are carried to the bench means 72 and 73for deposit thereon by lowering the hoists. Fastening devices 16 areused to anchor the sections to the bench means.

The machine has now been cleared for the previously adjusted sectionswhich were made ready on the beach means 70 and 71.

The hoists are moved along the overhead tracks to positions over thesections on the bench means 70 and 71 to connect the chains 104, forlifting the sections from the bench means after the drive chains havebeen released from the shafts 81 used in turning the mechanisms duringadjustment thereof and after the fastening devices 16 have been removed.

The sections now suspended by the hoists are quickly moved to a positionover the envelope making machine and lowered onto the seats 11, 12 and13. The fastening devices 16 are then inserted to anchor the sections inplace on the machine. It is to be understood that these sections havebeen adjusted so that the mechanisms thereof will operate upon theblanks 6.

The chain drives 61, 62 and 68 are then connected and the machine isready to start on the blanks 6. It is obvious that the changeoverrequires only a short time, so that the envelope making machine is soonback in service. Some minor adjustments may be required in the envelopemaking machine, but these are easily and quickly made.

With the machine 1 producing envelopes, work on adjusting the sectionson the bench means 72 and 73 is started, so that the adjustments arecompleted by the time the run of the blanks 6 is finished.

The removable sections may be of any number that is best adapted to thetype of envelope machine. Also, the

sections illustrated may be divided into smaller units, if desired.

What I claim and desire to secure by Letters Patent is: 1. The method ofadjusting an envelope making machine having a main drive and a series ofmechanisms for folding and sealing blanks into envelopes operable inconsecutive order and in timed relation with travel of the blanks forperforming the various operations on the blanks and which mechanisms areadjustable when changing over from the production of one size and styleof envelope to another, including the steps of:

removing a removable section carrying a plurality of said mechanismsinterconnected by a common drive as a unit, replacing said removablesection with a similar section interchangeable with the removablesection and in which the mechanisms have been adjusted while said firstnamed section is used in the machine, and connecting said similarsection by said common drive to the said main drive of said machine,whereby said machine is maintained in substantially continuousoperation. 2. The method as set forth in claim 1 wherein: said firstnamed removable section is lifted and conveyed from the machine and saidsimilar section is lifted and conveyed to the machine. 3. The method asset forth in claim 1, wherein: the mechanisms on said similar sectionare adjusted away from the machine through connection of drive means tosaid common drive.

References Cited UNITED STATES PATENTS 3,017,731 1/1962 Lohse 532013,186,316 6/1965 Lenk 93-62 BERNARD STICKNEY, Primary Examiner.

